Single trip multi-zone completion systems and methods

Abstract

Disclosed are systems and methods of producing from multiple production zones with a single trip multi-zone completion system. One method includes arranging an outer completion string within a wellbore adjacent the one or more formation zones, the outer completion string having at least one sand screen arranged thereabout and a flow control device movably disposed within the sand screen, locating an insert string within the outer completion string, the insert string having at least one control and data acquisition module disposed thereon that has one or more mechanical coupling mechanisms, locating the flow control device with the one or more mechanical coupling mechanisms, and moving the flow control device between a closed position and an open position with the one or more mechanical coupling mechanisms.

The invention claimed is: 
     
       1. A method of producing from one or more formation zones, comprising:
 arranging an outer completion string within a wellbore adjacent the one or more formation zones, the outer completion string having at least one sand screen arranged thereabout and a flow control device movably disposed within the at least one sand screen; 
 coupling the outer completion string to a production tubing; 
 locating an insert string within the outer completion string, the insert string having at least one control and data acquisition module disposed thereon and the at least one control and data acquisition module having one or more mechanical coupling mechanisms;
 wherein locating the insert string within the outer completion string further comprises communicably coupling the insert string to the outer completion string at a crossover coupling, the crossover coupling having one or more control lines coupled thereto; 
 wherein the one or more control lines extend external to the production tubing from a remote location to the crossover coupling; 
 
 extending a portion of the one or more control lines past the crossover coupling as a surveillance line, wherein the surveillance line extends externally along the outer surface of the outer completion string; 
 locating the flow control device with the one or more mechanical coupling mechanisms; and 
 moving the flow control device between a closed position and an open position with the one or more mechanical coupling mechanisms, wherein, when in the open position, fluids may communicate from the one or more formation zones, through the at least one sand screen, and into the outer completion string. 
 
     
     
       2. The method of  claim 1 , further comprising actuating the one or more mechanical coupling mechanisms in order to locate and move the flow control device. 
     
     
       3. The method of  claim 1 , further comprising varying a position of the flow control device in order to choke a fluid flow therethrough. 
     
     
       4. The method of  claim 1 , wherein moving the flow control device between the closed position and the open position further comprises:
 moving the flow control device partially between the closed and open positions; and 
 choking a fluid flow through the at least one sand screen. 
 
     
     
       5. The method of  claim 1 , further comprising:
 detaching the insert string from the outer completion string; 
 retrieving the insert string to a well surface while the outer completion string remains within the wellbore adjacent the one or more formation zones; 
 re-locating the insert string within the outer completion string; and 
 communicably coupling the insert string to the outer completion string at the crossover coupling. 
 
     
     
       6. A method of deploying a single trip multi-zone completion system, comprising:
 arranging an outer completion string within a wellbore that penetrates one or more formation zones, the outer completion string having at least one sand screen arranged thereabout and a flow control device movably disposed within the at least one sand screen; 
 coupling the outer completion string to a production tubing; 
 locating an inner service tool within the outer completion string; 
 treating the one or more formation zones with the inner service tool; 
 retrieving the inner service tool from within the outer completion string; 
 locating an insert string within the outer completion string, the insert string having at least one control and data acquisition module arranged therein; 
 wherein locating the insert string within the outer completion string further comprises communicably coupling the insert string to the outer completion string at a crossover coupling, the crossover coupling having one or more control lines coupled thereto; 
 wherein the one or more control lines extend external to the production tubing from a remote location to the crossover coupling; 
 extending a portion of the one or more control lines past the crossover coupling as a surveillance line, wherein the surveillance line extends externally along the outer surface of the outer completion string; and 
 locating and moving the flow control device with the at least one control and data acquisition module and thereby regulating a fluid flow through the at least one sand screen. 
 
     
     
       7. The method of  claim 6 , wherein locating and moving the flow control device with the at least one control and data acquisition module further comprises locating the flow control device with one or more mechanical coupling mechanisms extending from the at least one control and data acquisition module. 
     
     
       8. The method of  claim 6 , further comprising moving the flow control device between a closed position and an open position with the at least one control and data acquisition module, wherein, when in the open position, fluids may communicate from the one or more formation zones, through the at least one sand screen, and into the outer completion string. 
     
     
       9. The method of  claim 8 , further comprising:
 moving the flow control device partially between the closed and open positions; and 
 choking the fluid flow through the at least one sand screen. 
 
     
     
       10. The method of  claim 6 , further comprising varying a position of the flow control device in order to choke a fluid flow therethrough. 
     
     
       11. The method of  claim 6 , wherein treating the one or more formation zones comprises hydraulically fracturing and gravel packing the one or more formation zones.